Method and apparatus for forming, filling and sealing bags



Nov. 14, 1961 J. B. M CALLEY METHOD AND APPARATUS FOR FORMING, FILLING AND SEALING BAGS Filed Sept. 11, 1959 ll h.

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17 Sheets-Sheet 1 FIGURE *l INVENTOR Jane: 5. Ma CALLEV BY MM/ ATTORNEY Nov. 14, 1961 J. B. MCCALLEY 3,008,273

METHOD AND APPARATUS FOR FORMING, FILLING AND SEALING BAGS Filed Sept. 11, 1959 17 Sheets-Sheet 2 Nov. 14, 1961 B. MCCALLEY 3,008,273

METHOD AND APPARATUS FOR FORMING, FILLING AND SEALING BAGS Filed Sept. 11, 1959 17 Sheets-Sheet 3 FIGURE 3 FIGURE# 34 Jams: 6. M60440 Nov. 14, 1961 .1. B. M CALLEY 3,008,273

METHOD AND APPARATUS FOR FORMING. FILLING AND SEALING BAGS Filed Sept. 11, 1959 Y 17 Sheets-Sheet 4 FIGURE *5 Nov. 14, 1961 J. B. MOCALLEY METHOD AND APPARATUS FOR FORMING, FILLING AND SEALING BAGS Filed Sept. 11, 1959 17 Sheets-Sheet 5 INVENTOR JAMES B McC/mmr ATTORNEY Nov. 14, 1961 J. B. MCCALLEY METHOD AND APPARATUS FOR FORMING, FILLING AND SEALING BAGS Filed Sept. 11, 1959 17 Sheets-Sheet 6 m O 2 O m 1. a 2 O l .u w J .m n 2 2 l P l m u A0... 2 2 u a J a: n o m u n 2 FIGURE 8 FIGURE *9 INVENTOR JAMES B. Hcfaus Nov. 14, 1961 J. B. MOCALLEY 3,008,278

METHOD AND APPARATUS FOR FORMING, FILLING AND SEALING BAGS l7 Sheets-Sheet 7 Filed Sept. 11, 1959 AN-[5R Jnmzs 6. McCAuk YNf- ATTORNEY Nov. 14, 1961 J. B. MCCALLEY 3,008,278

METHOD AND APPARATUS FOR FORMING, FILLING AND SEALING BAGS Filed Sept. 11, 1959 17 Sheets-Sheet 8 Mov EMENT 2 INVENTOR JAMEJ 3 Mc CALLH ATTORNEY Nov. 14, 1961 J. B. MCCALLEY 3,008,273

METHOD AND APPARATUS FOR FORMING; FILLING AND SEALING BAGS Filed Sept. 11, 1959 17 Sheets-Sheet 9 FIGUREIZ-A Fueum: IZ

; lllll 3 :llliiliiii 1.

INVENTOR JAMzs McC/MLFH ATTORNEY Nov. 14, 1961 J. B. M CALLEY 3,008,273

METHOD AND APPARATUS FOR FORMING, FILLING AND SEALING BAGS Filed Sept. 11, 1959 17 Sheets-Sheet 1'0 i III;

FIGURE *IS llmmg r MOVEMENT 4 FIGURE *lS-A INVENTOR J1me; B. MCCALLEY ATTORNEY Nov. 14, 1961 J. B. M CALLEY METHOD AND APPARATUS FOR FORMING, FILLING ANDSEALING BAGS Filed Sept. 11, 1959 MOVEMENT 5 E t: i

FIGURE *I4 17 Sheets-Sheet l1 TNVENTOR JAMES B. N CALLEY ATTORNEY NOV. 1961 J. B. MCCALLEY 3,008,278

METHOD AND APPARATUS FOR FORMING, FILLING AND SEALING BAGS Filed Sept. 11, 1959 17 Sheets-Sheet 12 336 7' FIGURE *IS 4 l8 la v FIGURE #20 J Q! FIGURE IG F 2 IGURE gvwmm 17 Jams: 15. Mzfnusr Nov. 14, 1961 J. B. M CALLEY METHOD AND APPARATUS FOR FORMING, FILLING AND SEALING BAGS Filed Sept. 11, 1959 I46 u; n1

FIGURE *22 FIGURE 24 17 Sheets-Sheet 13 FIGURE 23 FIGURE 25 INVENTOR JAM ss 5. Mc CALLEY ATTORNEY Nov. 14, 1961 J. B. M CALLEY METHOD AND APPARATUS FOR FORMING, FILLING AND SEALING BAGS Filed Sept. 11, 1959 17 Sheets-Sheet 14 FIGURE 26 FIGURE 2? awe/Moo JAMES ,6. lWrCnutr Nov. 14, 1961 J. B. M CALLEY 3,008,278

METHOD AND APPARATUS FOR FORMING, FILLING AND SEALING BAGS Filed Sept. 11, 1959 -17 Sheets-Sheet 15 FIGURE 29 INVENTOR JAMS 5. Mc (ALLEY BY a J44 ATTORNEY Nov. 14, 1961 J. B. MOCALLEY 3,008,273

METHOD AND APPARATUS FOR FORMING, FILLING AND.SEALING BAGS Filed Sept. 11, 1959 17 Sheets-Sheet 16 FIGURE 30 Java 49 M4644? Nov. 14, 1961 J. B. M CALLEY 3,008,278

METHOD AND APPARATUS FOR FORMING, FILLING AND SEALING BAGS Filed Sept. 11, 1959 1'? Sheets-Sheet 17 FIGURE *32 INVENTOR JAMES B. Maw

ATTORNEY United States Patent O 3,008,278 METHOD AND APPARATUS FOR FORMING, FILLWG AND SEALING BAGS James B. McCalley, Calle 45 2401, Alturas tle Miramar, Marianao, Cuba Filed Sept. 11, 1959, Ser. No. 839,527 7 Claims. (Cl. 53-182) This invention relates to packaging and more particularly to a new and improved method and apparatus for continuously forming, filling and sealing bags from a web of sheet material such as cellophane, Wax paper or any other suitable packaging material.

FIELD OF INVENTION In the packaging of granular or other fluent material, such factors as speed of bag formation, effective closing and sealing of the bag and scams or edges, shielding the material in the bag being formed from damaging temperatures and pressures, and as well, the formation of a strong and attractive bag or package are bases of some of the more critical problems encountered. Concerning speed of bag formation, the use of apparatus by which a web of suitable bag forming sheet material is continuously formed into a tube to permit such successive operations as closing the free end of the tube, introducing the desired quantity of granular or other fluent material, sealing the upper edge of the bag and severing the bag thus formed from the continuously formed tubular portion has been particularly helpful. Generally, to enhance the rate at which completely formed bags may be produced on an apparatus of this type, the sealing action has been performed heretofore, in one operation, i.e., the upper edge of a lower bag and the lower edge of an upper bag are simultaneously heated under pressure to form a sealed zone, which Zone is severed centrally to separate one bag from the other. The difficulty with this technique of forming the end seals on the bags, however, is that first, only a single thickness of material is available for each side of the seal since folding the ends of the bags prior to scaling would require a separate and distinct operation, thus decreasing the overall rate of bag formation. Secondly, the strength of such a seal is often far below the strength required to package various matc rials particularly where rough handling and dense materials are involved.

Also, the problem of obtaining a satisfactory seal at the ends of bags thus formed continuously while at the same time leaving the material therein undamaged by the pressures and temperatures normally incurred in the sealing operation is one which has not been fully solved in apparatus and packaging techniques available to the industry prior to this invention. This problem becomes particularly critical in effecting or forming the top seal on each bag after it has been filled with a predetermined quantity of granular or fluid material since the source of heat normally used to produce this seal necessarily must be located close to the material in order to prevent the formation of only partially filled bags. Also, the seal formed at this point on the bag must be carried out with a minimum of handling since any undue folding and additional operations generally tend to damage the material in the bag.

To maintain the desired rate of bag forming speed, obtain a sufiiciently strong seal without in any way damaging the material with which the bags being formed are filled, and at the same time provide a bag or package which is neat in appearance poses an equally diflicult task to the packaging industry. In this respect, to achieve a neatly appearing bag, it is necessary if the ends thereof are to be folded to achieve proper strength, to form pleats or gussets in the sides of the bag being formed.

3,008,278 Patented Nov. 14, 1961 Although the formation of such gussets in bags is known in the packaging industry, their use in the continuous formation of bags is not without difiiculty. One of the principal reasons for this is that although the gussets may be readily formed for the sealing of the lower edge prior to filling, the introduction of material into the bag tends to remove any previously formed pleats or gussets. Hence, prior to effective and proper sealing of the upper bag edge, the gussets must be reformed over the level of material in the partially formed bag. In packaging techniques heretofore available, the lack of a satisfactory mode of forming and retaining the gussets often led to omitting them and thereby sacrificing the neat appearance rendered obtainable through their use.

Thus, while in general, the bag forming, filling and sealing techniques available to the packaging industry have, in the past, facilitated the rate at which bagging operations may be performed, many problems have gone unsolved. This is particularly significant in operations where the bags are formed, filled and sealed at the end of a continuously formed tube of bagging material where the speed potentials are great but where the quality of work is questionable for the reasons aforementioned.

OBJECTS I. A principal object of this invention is to provide a new and unique method of and apparatus for forming, filling and sealing packages such as bags by which the problems heretofore encountered are substantially overcome;

II. Another object of this invention is to provide a method of forming, filling and sealing bags which greatly enhances the appearance of the completely formed bag as well as the strength thereof;

III. A further object of this invention is that of providing an apparatus for completely forming filled bags from a continuously fed web of sheet material wherein substantially all of the bag forming operations are effected by power transmitted through a single rotary shaft;

IV. Another object of this invention is the provision of an apparatus for continuously forming and filling bags wherein the impact of material introduction is sustained completely on the bag forming mechanism and not on the bag material;

V. Another object of this invention is the provision of an apparatus for forming, filling and sealing bags whereby the ends of the bags are folded on themselves and then heat sealed to assure maximum strength;

VI. A further object of this invention is that of providing an apparatus of the referred type wherein highly effective means are provided for forming pleats or gussets in the sides of the bags being formed and as well, for retaining the gussets until the bags are sealed;

VII. Another object of this invention is the provision of an apparatus of the type referred to wherein means are provided for accurately registering the feed of bag forming material with the bag forming operation to enable the use of previously labeled material;

VIII. A still further object of this invention is the provision of an apparatus for forming, filling and sealing bags having gussets in the sides thereof, wherein the obstruction presented to the flow of material introduced into the bags by the gusset forming elements is eliminated such that the feed channel is left unblocked;

IX. Another and more specific object of this invention is that of providing in a machine of the referred type a carriage on which substantially all of the bag forming components are mounted and actuated automatically during movement of the carriage through its bag forming cycle.

Other objects and further scope of applicability of the present invention will become apparent from a detailed description given hereinafter. It should be understood, however, that the detailed description while indicating preferred embodiments of the invention, is given by way of illustration only, since it will become apparent to those skilled in the art from this description that various changes and modifications can be made without departing from the spirit and scope of this invention.

GENERAL DESCRIPTION In the new and improved packaging technique of this invention, the bag forming, filling and sealing operation is carried out by continuously forming a web of suitable sheet material such as, for example, cellophane, polyethylene, Wax paper, and the like into a tube, pleating the sides of the tube to establish gussets therein, and sealing the free end of the tube to form an open top partially formed bag. Thereafter, the partially formed bag is filled with a predetermined quantity of material and clamped along a line above the level of material in the bag and severed at a distance far enough from the clamping to permit folding over and sealing the upper edge of the bag. Prior to the cutting and sealing operations, however, and simultaneously with the clamping of the filled partially formed bags, the gussets previously folded in the tube and pushed outwardly during filling are reestablished so as to be incorporated in the upper seam.

The apparatus for performing this technique and ,to which this invention relates includes generally a frame, a crank actuated reciprocable carriage mechanism, a combination tubular feed chute and mandrel positioned above the can'rage associated with means for forming the web of bag forming material into a tube thereabout and a feeding mechanism positioned on the frame above the tubular mandrel and carriage. The mandrel carries centrally therein a pair of spaced plates which extend past the lower end of the mandrel and one of which is moveable with the reciprocating carriage. A pair of laterally moving plates are oscillatably supported on the frame so as to be insertable between the mandrel carried plates in a manner such that as the tube of bag forming material depends from the mandrel it is caused to be pleated at its sides to effect the formation of gussets therein. The carriage supports means for clamping the lower end of the tube depending from the mandrel as well as means for simultaneously folding the upper edge of a lower filled bag and the lower edge of an upper partially formed bag, separately actuated means for heat sealing these edges, means for severing the completely sealed bag from the partially formed bag tube and pair of fingers engageable with the side of the filled, partially formed bag for reforming the gussets therein after filling and before sealing. Except for the driving of an oscillatable metering feed cup arrangement at the top of the machine which moves from positions between a downwardly discharging hopper and the open upper end of the tubular mandrel for filling purposes, the entire operation of the bag forming elements is eifected by the engagement of various cam followers on respective cam plates mounted immovably on the frame. Thus, a complete cycle of operation or a complete bag is formed for each time the carriage moves from its uppermost limit of reciprocation to its lowermost position and back up again. Also, means are provided on the machine for registering the feed of bag forming sheet material with the movement of the carriage to permit the printing of labels on the web prior to the bag forming operation. p 7

A more complete understanding of the new and improved method and apparatus for forming, fillingand FIG. 3 is an enlarged fragmentary side elevation showing in detail the mechanism of this invention for continuously forming a web of sheet material into a tube;

FIG. 4 is an enlarged fragmentary plan view showing the improved forming and filling tubular mandrel of this invention;

FIG. 5 is a fragmentary cross-sectional view taken along line 55 of FIG. 4;

FIG. 6 is a fragmentary cross-sectional view taken along line 6-6 of FIG. 4;

FIG. 7 is an enlarged fragmentary plan view of the carriage mechanism of this invention taken along line 7-7 of FIG. 1;

FIG. 8' is a side elevation of the carriage shown in FIG. 7;

FIG. -9 is a side elevation of the carriage shown in FIG. 7 illustrating the side opposite that shown in FIG. 8;

FIG. 10 is a fragmentary cross-sectional view taken along line 10-40 of FIG. 7;

FIG. 11 is a fragmentary cross-sectional view taken along line 1010 of FIG. 7, and showing substantially the same carriage mechanism as FIG. 10, but in a different stage of operations;

FIG. 12 is a fragmentary cross-sectional view of the carriage mechanism shown in FIG. 10 but at another stage of operation;

FIG. 13 is a cross-sectional view of the mechanism shown in FIG. 10 at a more advanced stage of operation;

FIG. 14 is a cross-sectional view of the carriage and carriage components shown in FIGS. 10, ll, l2, 13 at its final stage of operation;

FIG. 15 is a fragmentary side elevation showing the respective carriage actuating cams of this invention;

FIG. 16 is a fragmentary cross-sectional view taken along line 1616 of FIG. 15;

FIG. 17 is a fragmentary front elevation of that portion of the machine shown in FIG. 15;

FIG. 18 is a fragmentary elevation taken along line 1818 of FIG. 16;

FIG. 19 is a plan view of the machine component shown in FIG. 18;

FIG. 20 is a fragmentary elevation taken along line 20-20 of FIG. 16;

FIG. 21 is a bottom plan view looking up at the ma-- chine element shown in FIG. 20;

FIG. 22 is an enlarged fragmentary side elevation showing the cutting knife actuating means of this invention;

FIG. 23 is a front elevation of the knife-actuating means shown in FIG. 21;

FIG. 24 is a side elevation of substantially the same components shown in FIG. 21 but in a different stage of operation;

FIG. 25 is a front elevation of the actuating means shown in FIG. 24;

FIG. 26 is a fragmentary elevation of the gusset folding or pleating mechanism of this invention;

FIG. 27 is a fragmentary plan view of the mechanism shown in FIG. 26;

FIG. 28 is a fragmentary elevation of substantially the same mechanism shown in FIG. 26, but in a dilferent stage of operation;

FIG. 29 is a fragmentary bottom plan view of the carriage shown in FIG. 7 illustrating the gusset reforming fingers of this invention, and as well, the actuating mechanism therefor;

FIG. 30 is an enlarged fragmentary front elevation of the feed hopper and metering apparatus of this invention;

FIG. 31 is a side elevation of the mechanism illustrated in FIG. 30;

FIG. 32 is a cross-sectional view taken along lines 3232 of FIGS. 30 and 31;

FIG. 33 is an enlarged fragmentary cross section of the carriage mechanism of this invention during the clamping and cutting stage of operation;

smears FIG. 34 shows substantially the same elements as FIG. 33, but during the initial folding stage of operation thereof;

FIG. 35 shows substantially the same organization as FIG. 33, but in the final folding stage of operation; and

FIG. 36 shows substantially the same elements as FIG. 33, but in the final heat sealing phase of operation.

DETAILED DESCRIPTION General organization and drive mechanism The general organization of the machine of this invention is shown in FIGS. 1 and 2 in which a frame generally designated by the numeral 10 is provided with a base 12, a pair of vertical upright members 14 and 16 respectively at the front thereof, a pair of rearwardly disposed frame portions designated by the numerals 18, 19 and 20. In addition to being assembled on the base, the front and rear vertical standards of the machine frame are connected by horizontal structural members 21, 22 and 23 and further the two sides of the frames thus established are connected at various levels by the horizontal structural members 24, 25 and 26. Also, a member 27 is provided and extends vertically between the horizontal members 22 and 23 on each side of the frame. The members 27 in turn support a horizontal extending bar 28.

The basic operating components of the machine forming the subject matter of this invention in terms of positions occupied on the frame may be referred to as a mechanism for feeding and measuring a specific quantity of material with which the bags formed by the machine are to be filled, which mechanism is generally designated by the numeral 30; a mechanism for forming a web of cellophane, wax paper or other material into a continuous tube from which the bags are ultimately formed, generally designated by the numeral 32; a vertically reciprocating carriage assembly designated generally by the numeral 34; and a drive mechanism generally designated by the numeral 36. Although the feeding mechanism 30, the tube forming mechanism 32 and carriage assembly 34 will be discussed in more detail hereinafter, the drive mechanism 36 is operated from a rotary input shaft 37 driven by a source of power such as a motor 38. From the shaft 37 the drive is through a gear box 39 to a rotary shaft 48 to which are keyed a pair of cranks 41 which in turn eccentrically carry crank pins 42 at one side of the shaft 40 and weights 44 at the opposite side therefrom for counterbalancing purposes. The pins 42 in turn are journaled in the ends of pitmans 45, which at their upper ends are journaled to bosses 46 on bars 47. One bar 47 is provided on each side of the carriage 34 and secured thereto such that vertical reciprocation of the bars 47 effects an equivalent movement of the carriage 34.

Connected to the carriage and vertically reciprocable therewith are a pair of rods 48 which extend upwardly to the feeding mechanism 30 for purposes which will be described more fully below. Also, for operating the feeding mechanism 30, a shaft 49 is drivingly connected to the gear box 39 to rotate a shaft 50 through link 51. A complete understanding of function of the rods 48 as well as the shaft 50 will be clear from the detailed description which follows below and they are referred to at this point only because of their relation to the drive mechanism.

Also, at this point, it will be noted that a bag discharge chute -2 is mounted in the vicinity of the drive mechanism and under the carriage 34. This chute is for the purpose of carrying the completed bags from the carriage clear of the machine for further handling. Further, it is preferred that this chute be associated with a conveyor, not shown, by which the bags may be automatically handled after their formation.

In the description which follows the feeding mechanism 30, the tube forming mechanism 32 and the carriage assembly 34 will be discussed under respective sub-titles.

6 Since these mechanisms co-act with one another in such a manner that one cannot be appreciated fully without having the other in mind, they will be taken up generally in the order in which they function to form, fill and seal bags.

The tube forming mechanism As shown in FIGS. 2 and 3 of the drawings,the mechanism for forming a continuous web of bag material into a tube includes a pair of brackets 53 rigidly mounted to each of the frame members 20 and which extend rearwardly of the machine terminating in a pair of bearings 54 for rotata-bly holding a spool 56 on which the web of material 58 to be used to form the bags is Wound. A canvas belt 60 equipped with a weight 62 at the lower end thereof is suspended from the frame members 20 over the spool to insure a sufiicient amount of resistance to unspooling of the web to prevent unwieldy slack there in. From the spool, the web is trained over a series of rollers, starting with the roller 64. The ends of the roller 64 are slidably received by angle members 66, which form with the frame members 18 and 19 a channel within which the roller may slide vertically to exert a desired tensioning in the web. The web is then trained over the roller 68, under the rollers 70 and 72 and over a roller 74. From the roller 74 the web is trained downwardly about roller 76 and is caused to pass a photoelectric cell designated by the numeral 78. The purpose of this cell is to enable registry of the labels printed or otherwise formed on the web to the bags as they are formed and the details thereof will be more fully explained hereinafter. From the roller 76, the web is trained over a curved surface collar 80 and thence downwardly about a tubular feed chute and mandrel 82.

The mandrel 82 is suspended from the top of the machine and more particularly from the apertured plate 84 suspended or carried on standards 86 mounted in the top of the machine frame as shown in FIGS. 1 and 2. The lower portion of the mandrel 82 is afforded stability to some extent by a circular collar 88 having a flanged base portion 90 so that it may be bolted, riveted or otherwise affixed to the crossbar 28 of the frame. The collar 88 fits loosely about the chute 82 so as to form an annulus through which the bag material may pass. Thus, it will be seen that the combination of the curved collar member 80, the tubular mandrel 82 and the collar 88 cause the web of bag material 58 to be continuously formed into a tube 58a.

Positioned immediately below the collar 88 on the periphery of the mandrel 82 is an elongated slightly projecting member designated by the numeral 92 in FIGS. 4. and 5 and having a serrated but generally fiat outer surface. A pivotable heat sealing member 94 is supported adjacent the projecting member 92 on a shaft 96 journaled in a bearing sleeve 98, which in turn is supported by a rod 100 extending perpendicularly thereto and affixed to the cross member 28 of the frame. The shaft 96 on which the heat sealing member 94 is carried is provided with a radially extending arm 102 to which one end of a spring 104 is attached. The opposite end of the spring 104 is affixed to the frame under tension so that the heat sealing member 94 is biased about its pivot into engagement With the serrated surfaced member 92. It will be noted that the inwardly facing surface of the heat sealing member is serrated to conform with the serrations on the member 92. The width of bag material and the diameter of the mandrel 82 are so established that when the bag material 58 is formed about the mandrel, the edges thereof overlap substantially the width of the member 92 and the heat sealing member 94, thus enabling a continuous seal of the tubular bag material as it passes the members 92 and 94.

Centrally positioned within the mandrel 82 are a pair of plates 106 and 108, both of which extend substantially diametrically across the tubular mandrel 82. Plate 106 is held stationary Within the tube by a pair of bracket 

